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WO2015128786A1 - Élément structural coulé - Google Patents

Élément structural coulé Download PDF

Info

Publication number
WO2015128786A1
WO2015128786A1 PCT/IB2015/051324 IB2015051324W WO2015128786A1 WO 2015128786 A1 WO2015128786 A1 WO 2015128786A1 IB 2015051324 W IB2015051324 W IB 2015051324W WO 2015128786 A1 WO2015128786 A1 WO 2015128786A1
Authority
WO
WIPO (PCT)
Prior art keywords
cast
structural element
structural
panel
insulation
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/IB2015/051324
Other languages
English (en)
Inventor
Heinrich Alfred SCHOLTEN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
WOLDT Roman
Original Assignee
WOLDT Roman
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by WOLDT Roman filed Critical WOLDT Roman
Publication of WO2015128786A1 publication Critical patent/WO2015128786A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2002/001—Mechanical features of panels
    • E04C2002/004—Panels with profiled edges, e.g. stepped, serrated

Definitions

  • This invention relates to a cast structural element used in the construction of buildings, walls and the like.
  • Buildings and walls are constructed using various techniques and structural elements. These include using building blocks such as bricks which are packed in off-set layers with mortar between adjoining bricks and layers to secure the bricks to each other.
  • Walls may also be created by placing panels between upright supports.
  • the panels may comprise precast concrete or cement, or fibrous or other compressed material in so-called dry-walling.
  • a wall is to be to cast-in-place, in which case formwork is constructed to define a volume that the wall will occupy once cast.
  • the formwork is filled with wet concrete or cement to fill the cavities and cure over time. Once cured sufficiently the formwork is removed to allow final curing of the wall.
  • buildings also require foundations, floors and ceilings.
  • ceilings In double storey buildings it is common for the ceiling of one level to function as the floor for the next level.
  • Such a floor or ceiling is commonly constructed by placing precast concrete slabs on support beams, or it is cast in situ.
  • insulation board is glued to the exterior of a single or double wall and rendered to harden and waterproof the wall. This leaves the insulation board vulnerable to environmental damage and aging.
  • a cast structural element which comprises a matrix of cast structural material at least partly containing a sheet of insulation material.
  • the cast structural material to comprise a cementitious material, preferably concrete or cement, and for the insulation material to preferably comprise magnesium oxide.
  • the structural element comprises a panel in abutment with an insulation material panel, preferably cast into abutment with it, alternatively for the structural element to comprise two panels between which an insulation material panel is located, preferably cast into abutment with it; and further preferably for the or each structural material panel to have the same length and height as the insulation material panel, and more preferably for the or each structural material panel to also have the same thickness as the insulation material panel.
  • the or both insulation material panels to extend from both ends of the cast structural element by a predetermined length equal to half of a predetermined mortar gap between adjoining cast structural element in a wall or floor to be formed by a plurality of the cast structural elements, as the case may be.
  • the or both insulation material panels to extend from one end of the cast structural element by a predetermined length equal to that of a predetermined mortar gap between adjoining cast structural element in a wall or floor to be formed by a plurality of the cast structural elements, as the case may be.
  • the structural element to comprise two outer structural material panels within which two insulation material panels are located spaced apart by a third centrally located structural material panel.
  • At least one reinforcing rod to be transversely embedded in the structural element to extend through the sheet of insulation material and at least partly into the cast structural material, and preferably into both structural material panels where the structural element comprises an insulation panel sandwiched between two cast structural material panels, and further preferably into both cast structural material panels adjacent each insulation panel where the structural element comprises two outer cast structural material panels within which two insulation material panels are located spaced apart by a centrally located cast structural material panel.
  • the cast structural element to comprise a building block, preferably having ends with complimentary shaped and sized engaging formations.
  • a building block that comprises two structural material panels between which an insulation material panel is located, to be formed by the one structural material panel being aligned fully with the insulation panel and the other structural material panel being offset in the length of the building block to extend at one end beyond the end of the aligned structural material panel and insulation panel, and at the other end of the building block for the end of the aligned structural material panel and insulation panel to extend beyond the end of the offset structural material panel, and preferably for the length by which the structural material panel is offset from the aligned structural material panel and insulation panel to correspond to the combined thickness of the aligned structural material panel and insulation panel.
  • a building block that comprises two outer structural material panels within which two insulation material panels are located spaced apart by a central structural material panel, to be formed by the building block having a stepped end at both ends along the longitudinal centre line of the third centrally located structural material panel, to form a building block with steps of equal length at both ends.
  • each structural material panel and each insulation panel to have a thickness of about 40mm.
  • the cast structural element prefferably be provided with a finished surface on at least one of its sides, and further for the finished surface to comprise a tile secured to such side.
  • a wall, floor or ceiling having a finished surface, preferably a tiled wall, floor or ceiling, comprising a plurality of structural elements with a finished surface contiguously arranged end to end with their finished surfaces all on one side.
  • a method for making a cast structural element which includes locating a sheet of insulation material in a mould, casting a structural material into the mould, and allowing the product to cure for a predetermined period until stable.
  • Figure 1 is a top perspective view of a representation of a structural element according to a first embodiment of the invention
  • Figure 2 shows an end-to-end arrangement between two structural elements of the embodiment shown in Figure 1 , and detail of the joint between them;
  • Figure 3 shows an intersecting joint, and detail thereof, of three structural elements according to the first embodiment of the invention shown in Figure 1 ;
  • Figure 4 is a top perspective view of a representation of a structural element according to a second embodiment of the invention.
  • Figure 5 is a perspective view of an end-to-end arrangement of two structural elements according to the second embodiment shown in Figure 4;
  • Figure 6 shows a top perspective view of a representation of an insulating sheet prior to being placed in a mould for structural material to be cast around it, with a plurality of transverse reinforcing rods through it;
  • Figure 7 is a top perspective view of a representation of a structural element according to a third embodiment of the invention. DETAILED DESCRIPTION OF THE INVENTION
  • FIG. 1 A first embodiment of a cast structural element (1 ) according to the invention is shown in Figures 1 to 3.
  • This cast structural element (1 ) comprises a matrix of cast structural material (2) at least partly containing a sheet of insulation material (3).
  • the structural material (2) comprises concrete and the insulating material (3) comprises magnesium oxide.
  • the insulating material (3) is provided in the form of a magnesium oxide panel (5) which is partially embedded within the concrete (4), having concrete (4) on both sides thereof to effectively sandwich it.
  • the concrete (4) is cast around the magnesium oxide panel (5) to bind with it and cure to form the structural element (1 ).
  • the structural element (1 ) thus comprises a cast building block (6) which can be used to construct a wall, floor panel or ceiling panel with integrated thermal insulation.
  • the building block (6) has offset ends (7A, 7B), with the insulating panel (3) being fully aligned with a panel of concrete (4A) on one end (7A) but with the second panel of concrete (4B) being offset by a predetermined length at the same end (7A) of the aligned insulating panel and first concrete panel. This creates a step (7) in the ends of the building block (6).
  • the insulating panel extends beyond both ends of the two panels (4A, 4B) between which is located. This provides a stepped end (7B) to the block that is different to the first described stepped end (7A).
  • step ends (7A, 7B) in the building block (6) allow for two blocks (6A, 6B) to be located end-to-end with the stepped ends (7A, 7B) dovetailing onto each other, whilst leaving a mortar gap (8A, 8B) of predetermined width between the aligned concrete panels of the two block (6A, 6B). This is shown in the detail of Figure.
  • This first embodiment of the cast structural element (1 ) according to the invention includes two concrete panels (4A, 4B) sandwiching a single insulating panel of magnesium oxide (5).
  • This provides a building block (6) which may be used for a single wall construction, floor panel or ceiling panel.
  • FIG. 4 A second embodiment of a cast structural element (20) according to the invention is shown in Figures 4 and 5.
  • This cast structural element (20) comprises a sandwich of two spaced apart insulating panels (21 A, 21 B) within a matrix of three spaced apart concrete panels (22A, 22B, 22C). It includes two outer concrete panels (22A, 22C) within which two insulation material panels (21 A, 21 B) are located spaced apart by a central concrete panel (22B).
  • This cast structural element (20) also forms a building block (23). It also includes stepped ends (24A, 24B) which allows for such blocks (23) to be located end-to-end (25) for structural integrity purposes, as shown in Figure 5.
  • the outer panels (22A, 22C) and the central panel (22B) of this cast structural element (20) are concrete panels.
  • the insulating panels (21 A, 21 B) are magnesium oxide panels.
  • the two insulating panels (21 A, 21 B) are located on opposite sides of the central concrete panel (22B), each having a concrete panel (22A, 22C) on its outside.
  • the centrally located concrete panel (22B) is stepped at its ends, with it being aligned at one end (24A) with the one insulating panel (21 B) and stepped out beyond the end of the other insulating panel (21 A), and at the other end (24B) being set back from both insulating panels (21 A, 21 B).
  • two blocks (23) of this second embodiment (20) may be aligned end to end to align and to provide mortar gaps (25-27) of predetermined thickness.
  • the building blocks (6, 23) are cast with each of the panels that comprise it having a typical thickness of about 40mm. This provides the first embodiment (6) with a thickness of about 120mm and the second embodiment (23) with a thickness of about 200mm, which is similar to standard single and double wall thicknesses.
  • the cast structural elements (1 , 20) don't only function as building blocks for walls. These may also be used for floors or ceilings.
  • the structural elements may be reinforced to allow it to bear weight, which is a requisite in some applications.
  • the integrated insulating panels within the cast structural elements have significant benefits. They provide predictable and consistent insulating properties to structures. The speed at which a building may be constructed using these structural elements is also increased since the phased construction of a double wall with insulating cladding in its centre is eliminated. The builder simply builds as if the building blocks were normal building blocks or bricks. Of course, if desired the structural elements may be produced with flat ends, i.e. having no offset ends. This may be useful for builders that wish to lay building blocks in a completely conventional manner, which does not use the offset ends or with mortar gaps. The size of the structural elements may also be modified to suit specific purposes.
  • the structural elements (1 , 20) are cast by creating a mould and locating one or more insulating panels within it, depending on the embodiment (1 , 20) of the structural element to be created.
  • the insulating panel has flat edges allowing it to stand on its edge in the mould.
  • the insulating panel (30) may be provided with reinforcing rods (31 ) that extend through it.
  • the length by which the ends of each rod (31 ) extend on the both sides of the insulating panel (30) is less than the thickness of the to-be cast concrete panel. This ensures that the rods (31 ) are completely contained within the final cast structural element on either side.
  • the panel (30) may be braced within the mould, for example by means of clamps to its upper edge. These can be removed once the mould has been filled, to allow for full contact between the concrete on the surfaces of the insulating panel (30).
  • edges of the insulating panel (30) are in contact with the bottom and ends of the mould, and the top edge of the insulating panel (30) is level with the top of the mould. This means the two concrete panels on opposite sides of the insulating panel do not contact each other, making for true sandwich configuration.
  • the insulating panel only with one edge, for example the bottom edge, against the mould surface. In such instance the ends and top edge of the insulating panel would not extend to the mould ends and top, allowing concrete to be cast around those edges of the insulating panel.
  • FIG. 7 A third embodiment (40) of a cast structural element according to the invention is shown in Figure 7.
  • an insulation panel (41 ) of magnesium oxide is located between two cast concrete panels (42A, 42B).
  • a ceramic tile (43A, 43B) To the outer surface of each concrete panel (42A, 42B) there is affixed a ceramic tile (43A, 43B), having the same length and width as the two panels (42A, 42B).
  • This allows the building block (40) so-formed to be used as block in wall that is intended to have a tiled surface on both sides, for example for an inner wall in a building.
  • the block (40) is thus provided with a finished surface (in the form of the ceramic tile).
  • surface finishes other than ceramic tiles may be used, for example porcelain tiles, or other types of decorative surface finishes.
  • insulating material other than a magnesium oxide panel. It is also possible to use a structural material other than concrete, for example other cementitious materials.
  • the cast structural element with engaging formations other than one the ends thereof. It is for example possible to form complimentary engaging formations along the top and bottom edges thereof. It is also possible to form engaging formations other than steps, for example by forming a tongue and groove formation at the ends or along the top and bottom edges.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Building Environments (AREA)

Abstract

L'invention concerne un élément structurel coulé (1), qui comprend une matrice de matériau structural coulé (2) contenant au moins partiellement une feuille de matériau isolant (3), le matériau structural coulé (2) comprenant de préférence un matériau à base de ciment, et le matériau isolant (3) comprenant de l'oxyde de magnésium.
PCT/IB2015/051324 2014-02-25 2015-02-21 Élément structural coulé Ceased WO2015128786A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ZA201401406 2014-02-25
ZA2014/01406 2014-02-25

Publications (1)

Publication Number Publication Date
WO2015128786A1 true WO2015128786A1 (fr) 2015-09-03

Family

ID=54008246

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2015/051324 Ceased WO2015128786A1 (fr) 2014-02-25 2015-02-21 Élément structural coulé

Country Status (1)

Country Link
WO (1) WO2015128786A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10287770B2 (en) 2015-11-04 2019-05-14 Omnis Advanced Technologies Systems, methods, apparatus, and compositions for building materials and construction

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4974381A (en) * 1989-07-27 1990-12-04 Marks Karl R Tie anchor and method for manufacturing insulated concrete sandwich panels
DE10147409A1 (de) * 2001-09-26 2003-04-17 Hochtief Fertigteilbau Gmbh Wärmeisolierendes, tragfähiges Bauelement und Verfahren zu seiner Herstellung
CN201212189Y (zh) * 2008-06-18 2009-03-25 支亮 防火型泡沫夹芯板
WO2012048367A1 (fr) * 2010-10-11 2012-04-19 Fbm Corporation Pty Ltd Panneau de construction, système de construction et procédé de construction d'un bâtiment

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4974381A (en) * 1989-07-27 1990-12-04 Marks Karl R Tie anchor and method for manufacturing insulated concrete sandwich panels
DE10147409A1 (de) * 2001-09-26 2003-04-17 Hochtief Fertigteilbau Gmbh Wärmeisolierendes, tragfähiges Bauelement und Verfahren zu seiner Herstellung
CN201212189Y (zh) * 2008-06-18 2009-03-25 支亮 防火型泡沫夹芯板
WO2012048367A1 (fr) * 2010-10-11 2012-04-19 Fbm Corporation Pty Ltd Panneau de construction, système de construction et procédé de construction d'un bâtiment

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10287770B2 (en) 2015-11-04 2019-05-14 Omnis Advanced Technologies Systems, methods, apparatus, and compositions for building materials and construction
US10745905B2 (en) 2015-11-04 2020-08-18 Omnis Advanced Technologies, LLC Systems, methods, apparatus, and compositions for building materials and construction

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